Fluid Domain Characteristics and Separation Performance of an Eccentric Pipe Separator Handling a Crude Oil-Water Mixture

This study presents an eccentric pipe separator (EPS) designed according to the shallow pool principle and Stokes’ law as a compact alternative to conventional gravitational tank separators for offshore platforms. To investigate the internal oil-water flow characteristics and separation performance of the EPS, both field experiments with crude oil on an offshore platform and computational fluid dynamics (CFD) simulations were conducted, guided by dimensional analysis. Crude oil volume fractions were measured using a Coriolis mass flow meter and the fluorescence method. The CFD analysis employed an Eulerian multiphase model coupled with the renormalization group (RNG) k-ε turbulence model, validated against experimental data. Under the operating conditions examined, the separated water contained less than 50 mg/L of oil, while the separated crude oil achieved a purity of 98%, corresponding to a separation efficiency of 97%. The split ratios between the oil and upper outlets were found to strongly influence the phase distribution, velocity field, and pressure distribution within the EPS. Higher split ratios caused crude oil to accumulate in the upper core region and annulus. Maximum separation efficiency occurred when the combined split ratio of the upper and oil outlets matched the inlet oil volume fraction. Excessively high split ratios led to excessive water entrainment in the separated oil, whereas excessively low ratios resulted in excessive oil entrainment in the separated water. Crude oil density and inlet velocity exhibited an inverse relationship with separation efficiency; as these parameters increased, reduced droplet settling diminished optimal efficiency. In contrast, crude oil viscosity showed a positive correlation with the pressure drop between the inlet and oil outlet. Overall, the EPS demonstrates a viable, space-efficient alternative for oil-water separation in offshore oil production.